A mold powder for continuous steel casting, contains cao, SiO2 and fluoride as the main components. The ratio by weight of cao', represented by the following equation, to SiO2 is 0.9-2.8 and the CaF2 content is about 5-60 wt. %. The powder contains Na2 O in an amount of 0-25 wt. % and C in an amount of 0-10 wt. %.
cao'=T.cao-F×(56/38)
wherein T.cao represents the total Ca content in the mold powder as converted to cao(wt. %) and F represents the total F content in the mold powder(wt. %). The powder is used in a method for continuous steel casting.
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1. A mold powder for continuous steel casting, containing cao, SiO2 and fluoride as the main components, wherein the ratio by weight of cao', represented by the following Equation (X), to SiO2, cao'/SiO2, is 0.9-2.8 and the CaF2 content represented by the following Equation (Y) satisfies either of the following Condition (A) or (B), and further containing Na2 O in an amount of 0-25 wt. % and C in an amount of 0-10 wt. %:
(A) if cao'/SiO2 is not less than 0.9 and not greater than 1.9, the CaF2 content is 15-60 wt. %; (B) if cao'/SiO2 is greater than 1.9 and not greater than 2.8, the CaF2 content is 5-60 wt. %,
wherein cao'=T.cao-F×(56/38) (X), CaF2 =F×(78/38) (Y), T.cao: the total Ca content in the mold powder as converted to cao (wt. %), and F: the total F content in the mold powder (wt. %). 13. A method for continuously casting steel by use of a mold powder containing cao, SiO2 and fluoride as the main components, wherein the ratio by weight of cao', represented by the following Equation (X), to SiO2, cao'/SiO2, is 0.9-2.8 and the CaF2 content represented by the following Equation (Y) satisfies either of the following Condition (A) or (B), and further containing Na2 O in an amount of 0-25 wt. % and C in an amount of 0-10 wt. %:
(A) if cao'/SiO2 is not less than 0.9 and not greater than 1.9, the CaF2 content is 15-60 wt. %; (B) if cao'/SiO2 is greater than 1.9 and not greater than 2.8, the CaF2 content is 5-60 wt. %,
wherein cao'=T.cao-F×(56/38) (X), CaF2 =F×(78/38) (Y), T.cao: the total Ca content in the mold powder as converted to cao (wt. %), and F: the total F content in the mold powder (wt. %). 2. The mold powder for continuous steel casting according to
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1. Field of the Invention
The present invention relates to a mold powder for continuous casting which enables manufacture of a slab having excellent surface quality in the casting of steel at a high casting speed. The present invention also relates to a continuous casting method using the mold powder of this invention.
2. Description of the Related Art
Steel plates for use in outer parts of automobiles, which require excellent surface quality and high cold workability, are generally manufactured from continuously cast slabs having a thickness of about 250 mm. This is because slabs having both excellent surface quality and internal quality are required, along with high slab productivity. The casting speed is generally 2-3 m/min. A casting speed greater than this results in defects, including longitudinal cracks on the surface of a slab and residual non-metal inclusions in the slab.
On the other hand, for the past several years, there has been developed a mini-mill in which a thin slab continuous casting machine and a simple hot rolling machine are disposed in a same production line. In the method of thin slab continuous casting, from the viewpoint of productivity, a casting speed of at least about 5 m/min is the target speed to attain.
Since molten medium carbon steel causes peritectic reaction when solidified, the surface of a slab made of such steel is susceptible to longitudinal cracks. If the medium carbon steel is cast by thin slab continuous casting at a high casting speed, longitudinal cracking on its slab surface is accelerated. Also, low alloy steel often suffers longitudinal cracks on its slab surface if the low alloy steel contains an alloy element which increases susceptibility to cracking.
It is well known that a strong relationship exists between longitudinal cracking on the slab surface and mold powder. In continuous casting, molten steel is fed into a mold through an immersion nozzle, and a mold powder is applied onto the surface of the molten steel in the mold under casting. Typically, the mold powder comprises a mixture of one or more types of oxides and carbon powder or others. The mold powder added to a mold is melted by the heat of the molten steel, to thereby form a molten slag layer on the surface of the molten steel. The molten slag layer flows into the gap between a mold surface and a solidified shell, to thereby form a slag film. The slag film is cooled while in contact with the mold surface and solidified. The solidified slag film is composed of crystal and glass.
The mold powder showing the above properties has the following effects:
1) maintaining temperature of the molten steel surface in a mold and preventing oxidation of the molten steel,
2) absorbing bubbles and inclusions which are present in molten steel and float on the surface thereof,
3) securing lubrication between a mold surface and a solidified shell, and
4) adjusting cooling rate of a solidified shell through adjusting heat resistance of molten slag layer.
Of these effects, item 3), securing lubrication, is particularly important in casting at high casting speed. Also, item 4), adjusting cooling rate of the solidified shell within a mold, i.e. a slab surface, in the early stage of solidifing, is important for preventing longitudinal cracks on a slab surface.
Generally, if casting speed is increased in continuous casting, the amount of molten slag flowing into the gap between a mold surface and a solidified shell decreases. If the amount of molten slag flowing into the gap and the slag film thickness decrease accordingly, the solidified shell is restrained on the mold surface due to poor lubrication. In the worst case, this may lead to operational accidents such as breakout. In order to secure the amount of molten slag flowing into the gap, the solidification temperature of the molten slag is lowered or the viscosity of the molten slag is lowered. However, lowered solidification temperature or viscosity of molten slag often impairs uniformity of the thickness of a slag film. Consequently, the cooling rate of the solidified shell within the mold lacks uniformity, so that the slab becomes susceptible to longitudinal cracks. Therefore, an important technical objective is to create a mold powder which imparts both lubrication, which is effective in increasing the casting speed, and uniformity of cooling rate of a solidified shell, which is effective in prevention of longitudinal cracks on a slab surface.
For prevention of longitudinal cracks on a slab surface in casting at high casting speed, the following methods have been proposed: In Japanese Patent Application Laid-Open (kokai) No. 3-193248 is proposed a method of incorporating into mold powder, as accelerators of crystallization, oxides of elements belonging to Group IIIA and Group IV such as ZrO2, TiO2, Sc2 O3, and Y2 O3. Further, according to this invention a high casting speed is achieved if the viscosity of a molten slag is lowered to 1 poise or less at 1300°C In the course of being cooled, the molten slag produces crystals which mildly cool the slab surface within a mold. This mild cooling of the slab surface makes the cooling rate of the slab surface uniform.
Also, in Japanese Patent Application Laid-Open (kokai) No. 5-15955 are proposed lowering the viscosity of a molten slag and increasing the ratio by weight of T.CaO to SiO2 (T.CaO/SiO2). In this method, T.CaO represents a sum of the amount of CaO contained in the mold powder and the amount of CaO converted from Ca-containing matter assumed to be present in the mold powder in the form of CaF2, and is defined by the following equation (Z).
T.CaO (wt. %)=CaO (wt. %)+CaF2 (wt. %)×(56/78) (Z)
In this invention, if T.CaO/SiO2 is increased to as much as about 1.2 to 1.3, crystallization occurs in the cooling process of a molten slag, by which the slab surface within the mold is cooled mildly.
However, in the case where the mold powders proposed in the above-mentioned Japanese Patent Application Laid-Open (kokai) Nos. 3-193248 and 5-15955 are used in casting medium carbon steel containing peritectic steel, if the casting speed exceeds a certain value, mild cooling effect of a molten slag to the mold surface becomes insufficient, resulting in longitudinal cracking on the slab surface. Briefly, use of these mold powders at a casting speed of about 2-3 m/min or more may result in longitudinal cracking on the slab surface.
Apart from the above-mentioned inventions, a mold powder having a high T.CaO/SiO2 ratio is proposed in Japanese Patent Application Laid-Open (kokai) No. 5-269560. This mold powder has a CaO/SiO2 ratio of 1.1-1.8, and has a CaO/F ratio of 9-40.
Further, in Japanese Patent Application (filed in 1978) Laid-Open (kokai) No. 54-35129, a mold powder having a relatively high CaO/SiO2 ratio is proposed. This mold powder has a CaO/SiO2 ratio of 0.6-1.4, and contains fluorspar in an maximum amount of 10 wt. %.
As mentioned above, in order to prevent longitudinal cracks on a slab surface in casting medium carbon steel, low alloy steel, or low carbon steel at a casting speed of about 5 m/min or higher, the performance of mold powder is required to be further improved.
An object of the present invention is to provide a mold powder which is advantageously used in high-speed casting such as thin slab continuous casting, or in continuous casting of steel such as medium carbon steel which is susceptible to longitudinal cracks.
The mold powder for continuous steel casting according to the present invention contains CaO, SiO2, and fluoride as the main components. Also, in this mold powder, the ratio by weight of CaO', represented by the following Equation (X), to SiO2, i.e. CaO'/SiO2, is 0.9-2.8, and the CaF2 content, represented by the following Equation (Y), satisfies either of the following Condition (A) or (B). Further, this mold powder contains Na2 O in an amount of 0-25 wt. % and C in an amount of 0-10 wt. %.
(A) If CaO'/SiO2 is not less than 0.9 and not greater than 1.9, the CaF2 content is 15-60 wt. %, or
(B) If CaO'/SiO2 is greater than 1.9 and not greater than 2.8, the CaF2 content is 5-60 wt. %,
wherein
CaO'=T.CaO-F×(56/38) (X),
CaF2 =F×(78/38) (Y),
T.CaO: the total Ca content in the mold powder as converted to CaO (wt. %), and
F: the total F content in the mold powder (wt. %).
Specifically, under Condition (A) above, the CaF2 content is preferably 20-60 wt. %. More preferably, CaO'/SiO2 is 1.1-1.7 and the CaF2 content is 25-50 wt. %. Under these conditions, longitudinal cracking in a slab is effectively prevented. Under Condition (B) above, CaO'/SiO2 is preferably 2.1-2.6 and the CaF2 content is preferably 25-50 wt. %. Under these conditions also, longitudinal cracking in a slab is effectively prevented.
The mold powder according to the present invention has a solidification temperature suitable for Continuous steel casting. If the solidification temperature is required to be lowered to a more suitable solidification temperature, Na2 O in an amount of 2-25 wt. % is preferably incorporated into the mold powder. If the melting rate of the mold powder is required to be adjusted to a more suitable melting rate, C in an amount of 1-10 wt. % is preferably incorporated into the mold powder.
So long as the chemical composition of the mold powder falls within the above-mentioned scope and its viscosity at 1300°C does not exceed 1.5 poise, sufficient lubrication is obtained even if the mold powder is applied in continuous steel casting at a high casting speed of 5 m/min or more.
By use of the mold powder of the present invention, continuous steel casting at a high casting speed can be performed without longitudinal cracking. Preferably, the mold powder of the present invention is used in casting of steel containing C in an amount of 0.05-0.20%. The mold powder of the present invention is especially effective in casting of peritectic steel containing C in an amount of 0.08-0.20%. Also the mold powder of the present invention is advantageously applied in casting of low alloy steel containing C in an amount of 0.05-0.20% and an alloy element enhancing susceptibility to cracking on a slab, such as Mn, Cr, Ni, Ti, Mo, Nb, or V. Further, the mold powder of the present invention is advantageously applied in casting of steel containing C in an amount of about 0.05% at a high casting speed of 5 m/min or higher.
The mold powder of the present invention has an increased CaO'/SiO2 ratio, i.e. basicity, and produces a greater amount of crystals in the process where the mold powder in a molten state is solidified. However, if merely the basicity of the mold powder is increased, its solidification temperature is also increased, with the result that casting steel at a high casting speed is difficult. In light of the foregoing, the present inventors have solved the problem involving the conflicting properties of mold powder, i.e. the problem in which increased basicity leads to highered solidification temperature, by the following Means (a) and (b):
(a) Acceleration of Crystallization in Molten Slag
An important factor for prevention of longitudinal cracks in a slab is the uniformity of cooling rate of the solidified shell within a mold, i.e. a slab surface in the early stage of solidifing. If the cooling rate of the slab surface in the early stage of solidifing is not uniform, the thickness of the solidified shell lacks uniformity in the lateral direction of the slab. Consequently, the stress acting on the solidified shell due to shell shrinkage during solidifing is not uniformly alleviated in the lateral direction of the slab, so that longitudinal cracks are formed on the surface of the slab.
Increasing the heat resistance of a slag film formed between the mold and the solidified shell is an important factor for realizing uniform cooling of the solidified shell through the slag film. If the heat resistance of the slag film is low, the solidified shell is considerably affected by variations in cooling effect at a variety of portions of the mold. In this case, the variation of the cooling rate of the solidified shell becomes significant, and the thickness of the solidified shell lacks uniformity in the lateral direction of the mold. In contrast, if the heat resistance of the slag film is increased and the solidified shell is mildly cooled, the thickness of the solidified shell becomes uniform in the lateral direction of the mold, with the result that longitudinal cracks on the slab surface are prevented.
With regard to the mold powder of the present invention, a new index, i.e. CaO'/SiO2 represented by Equations (X) and (Y) above, is employed in place of a conventional index, i.e. T.CaO/SiO2, to thereby enable selection of a ternary composition containing CaO--SiO2 --CaF2 as the main components by which crystallization easily occurred. With this selection, more crystallization occurs in the solidification process of molten slag, resulting in higher heat resistance of molten slag.
In a ternary composition of a mold powder containing CaO--SiO2 --CaF2 as the main components, the mold powder of the present invention has a high CaO'/SiO2. Therefore, more crystallization occurs in the solidification process of a molten slag. Specifically, CaO'/SiO2 is as high as 0.9-2.8, resulting in an increase in the amount of crystallization.
(b) Lowering Viscosity and Rationalization of Solidification Temperature and Melting Rate in High-basicity Mold Powder
The thickness of a slag film under continuous steel casting depends on the amount of molten slag flowing into the gap between a mold surface and the solidified shell within a mold. If an excessively large amount of molten slag flows into the gap, there results a large difference between the thickness of a slag film portion where the amount of molten slag is large and that where the amount of molten slag is small, with the result that the cooling rate of the solidified shell lacks uniformity. In contrast, if an excessively small amount of molten slag flows into the gap, the overall thickness of a slag film is small. In this case, a slight difference in a slag film thickness often leads to non-uniform cooling rate of the solidified shell. As mentioned above, regardless of whether an excessively large or small amount of molten slag flows into the gap, longitudinal cracks are formed in a slab. In addition, an extremely small amount of molten slag flowing into the gap may cause an operational accident such as breakout.
Especially in casting at high casting speed, the amount of molten slag flowing into the gap between a mold surface and the solidified shell within a mold tends to decrease. Therefore, an important technical objective is securing the thickness of slag film and making it uniform.
Generally, the thickness of a slag film can be controlled through adjustment of the melting point of mold powder and viscosity of mold powder in a molten state. Since the mold powder of the present invention has a ternary composition containing CaO--SiO2 --CaF2 as the main components and the above-mentioned value of CaO'/SiO2 is large, the mold powder generally has a high solidification temperature.
The mold powder of the present invention contains a relatively large amount of CaF2, so as to lower the solidification temperature and viscosity of the molten slag. That is, if CaO'/SiO2 is 0.9-1.9, suitable melting point and viscosity are obtained through incorporation of 15-60 wt. % of CaF2 into the mold powder. If CaO'/SiO2 is greater than 1.9 and not greater than 2.8, suitable solidification temperature and viscosity are obtained through incorporation of 5-60 wt. % of CaF2 into the moldpowder.
FIG. 1 is a ternary (CaO'--SiO2 --CaF2) chemical composition diagram showing the scope of the chemical composition of the mold powder of the present invention.
FIG. 2 is a graph showing the relationship between the crystallization index of crystallization from the mold powder of the present invention in a molten state and CaO'/SiO2.
FIG. 3 is a graph showing the relationship between the crystallization index of crystallization from the mold powder of the present invention in a molten state and CaF2 content.
Next a powder of the present invention and a continuous casting method using the same will be described. The symbol "%" indicative of content in chemical composition means "% by weight."
Three main components of the mold powder of the present invention are CaO, SiO2, and fluoride. Their approximate contents are as follows: CaO; 25-70%, SiO2 ; 15-35%, and fluoride; about 5-60% (as CaF2). In the present invention, the most important factors are the ratio of CaO' to SiO2 (CaO'/SiO2) and CaF2 content.
The mold powder of the present invention produces a large amount of crystals in the process of cooling and solidification of the mold powder in a molten state. When crystallization occurs, heat resistance becomes higher as mentioned above. As a result, a slag film present between a mold surface and the solidified shell within a mold exerts an effect of preventing rapid cooling of the solidified shell, i.e. the slab surface. Next a suitable scope of the chemical composition of the mold powder of the present invention will be described, in connection with crystallization in the cooling process of a molten slag.
(CaO'/SiO2)
CaO' used in calculation of the ratio of CaO' to SiO2 (CaO'/SiO2) defined in the present invention is obtained through Equations (X) and (Y) mentioned above. In other words, CaO' is not equal to CaO which is obtained on the assumption of the analyzed value of T. Ca in a mold powder represents solely CaO. First, the CaF2 content is obtained through Equation (Y), mentioned above, on the assumption that all F exists in the form of CaF2 based on the analyzed value of F. Next, CaO' is obtained on the assumption that total Ca content minus Ca present in the form of CaF2 equals CaO content. The value of SiO2 is obtained based on the analyzed value of Si contained in the mold powder.
In the mold powder of the present invention, the CaO'/SiO2 ratio is not less than 0.9 and not greater than 2.8. So long as the CaO'/SiO2 ratio falls within this range, a sufficient amount of crystallization occurs when a molten slag is cooled and solidified. If the CaO'/SiO2 ratio is less than 0.9, an insufficient amount of crystallization occurs. If the CaO'/SiO2 ratio exceeds 2.8, the mold powder has an excessive high solidification temperature. As a result, during steel casting, the mold powder is difficult to melt at the temperature of molten steel. In this case, rationalization of the thickness of a molten slag on the molten steel surface, within a mold, and the thickness of a slag film formed between a mold surface and the solidified shell of a slab becomes difficult, resulting in accidents in continuous casting operation. Therefore, the CaO'/SiO2 ratio is 0.9-2.8.
As mentioned below, if the CaO'/SiO2 ratio is around 1.9, 0.9, or 2.8, crystallization does not occur easily. Therefore, the most preferable ranges of CaO'/SiO2 ratio are 1.1-1.7 and 2.1-2.6.
(CaF2 content)
The CaF2 content defined in the present invention is obtained through the above-mentioned Equation (Y). That is, a CaF2 content is the value converted to CaF2 based on the analyzed value of F contained in all fluorides such as NaF and CaF2. However, most fluorides incorporated into the mold powder of the present invention are in the form of CaF2.
In the mold powders of the present invention, the proper CaF2 content is 15-60% if the CaO'/SiO2 ratio is 0.9-1.9; or 5-60% if the CaO'/SiO2 ratio is greater than 1.9 and not greater than 2.8. So long as the CaF2 content falls within either of these ranges, a sufficient amount of crystallization occurs when a molten slag is cooled and solidified.
FIG. 1 is a ternary (CaO'--SiO2 --CaF2) chemical composition diagram for explaining the scope of the chemical composition of the mold powder of the present invention. Since most fluorides incorporated into the mold powders of the present invention are in the form of CaF2, the CaO' content calculated through Equations (X) and (Y) above, substantially equals CaO content. Therefore, for the purpose of convenience, the mold powders of the present invention will be described with reference to the above-mentioned ternary (CaO'13 SiO2 --CaF2) chemical composition diagram.
As shown in FIG. 1, the chemical composition of the mold powder of the present invention in which the CaO'/SiO2 ratio is 0.9-1.9 and the CaF2 content is 15-60 wt. % falls within region (a), i.e. the region defined by Border Line 1 on which the CaO'/SiO2 ratio is 0.9 (the straight line from CaO·SiO2 to 100 wt. % CaF2); Border Line 2 on which the CaO'/SiO2 ratio is 1.9 (the straight line from 2CaO·SiO2 to 100 wt. % CaF2), the straight line on which the CaF2 content is 15 wt. %, and the straight line on which the CaF2 content is 60 wt. %.
The chemical composition of the mold powder of the present invention in which the CaO'/SiO2 ratio is greater than 1.9 and not greater than 2.8 and the CaF2 content is 5-60 wt. % falls within region (b), that is, the region defined by Border Line 2 on which the CaO'/SiO2 ratio is 1.9; Border Line 3 on which CaO'/SiO2 is 2.9 (the straight line from 3CaO·SiO2 to 100 wt. % CaF2), the straight line on which the CaF2 content is 5 wt. %, and the straight line on which the CaF2 content is 60 wt. %.
For the purpose of comparison, the chemical composition of a conventional mold powder for mild cooling of a solidified shell is indicated by region (c). In addition, the chemical composition of the aforementioned high-basicity conventional mold powder for preventing erosion of immersion nozzles is indicated by region (d). It is apparent that the mold powder of the present invention has a CaO'/SiO2 ratio, i.e. a basicity, higher than that of conventional mold powders.
If the CaO'/SiO2 ratio is 0.9-1.9 and the CaF2 content is 15-60%, a large amount of crystals called cuspidine represented by a molecular formula 3CaO·2SiO2 ·CaF2 or 3CaO·2SiO2 crystallize in the cooling process of a molten slag. FIG. 2 shows the relationship between the crystallization index of cuspidine crystallizing from the molten slag and CaO'/SiO2 ratio. If the CaO'/SiO2 ratio is 0.9-1.9 a large amount of crystallization occurs, whereas if the CaO'/SiO2 ratio is less than 0.9 a small amount of crystallization occurs. For this reason, the conventional mold powders have an insufficient mild cooling effect and result in longitudinal cracking on slab surfaces. Also, as is apparent from FIG. 2, regarding the case in which the CaO'/SiO2 ratio is 0.9-1.9, the range 1.1-1.7 is preferred.
FIG. 3 is a graph showing the influence of the CaF2 content on the amount of crystallization mainly consisting of cuspidines. If the CaF2 content is 15% or more, the amount of crystallization becomes considerably large, whereas if the CaF2 content exceeds 60%, the amount of crystallization becomes small. If the CaF2 content exceeds 60%, a immersion nozzle becomes susceptible to erosion by molten slag.
Consequently, in the case where the CaO'/SiO2 ratio is 0.9-1.9, the CaF2 content is preferably 15-60%, more preferably 20-60%, most preferably 25-50%. The most preferable combination of CaO'/SiO2 ratio and CaF2 content falls within the range where the CaO'/SiO2 ratio is 1.1-1.7 and the CaF2 content is 25-50%.
If the CaO'/SiO2 ratio is greater than 1.9 and not greater than 2.8, crystals represented by a molecular formula (6-x) CaO·2SiO2 ·xCaF2 (x: an arbitrary number of 0-6) or 4CaO·2SiO2 ·CaF2 crystallize in the cooling process of a molten slag. FIG. 2 shows the relationship between the crystallization index of these crystals and the CaO'/SiO2 ratio. If the CaO'/SiO2 ratio is greater than 1.9 and not greater than 2.8, a large amount of crystallization occurs. In this case, it is characteristic that different crystals of various kinds crystallize in a large amount, as compared with the case where the CaO'/SiO2 ratio is 0.9-1.9. As is apparent from FIG. 2, if the CaO'/SiO2 ratio is greater than 1.9 and not greater than 2.8, the preferable range is 2.1-2.6.
FIG. 3 shows the relationship between the crystallization index and the CaF2 content in the case where the CaO'/SiO2 ratio is greater than 1.9 and not greater than 2.8. When the CaF2 content exceeds 5%, the crystallization amount increases remarkably. Since the CaO'/SiO2 ratio is large, crystals tend to crystallize easily irrespective of a low CaF2 content.
When the CaF2 content exceeds 60%, the crystallization amount of these crystals considerably decreases and an immersion nozzle becomes susceptible to erosion by molten slag.
Consequently, in the case where the CaO'/SiO2 ratio is greater than 1.9 and not greater than 2.8, the CaF2 content is preferably 5-60%, more preferably 20-60%, most preferably 25-50%. The most preferable combination of CaO'/SiO2 ratio and CaF2 content falls within the range where the CaO'/SiO2 ratio is 2.1-2.6 and the CaF2 content is 25-50%.
As mentioned above, in casting at a casting speed of 5 m/min or higher, securing the thickness of a slag film is difficult. In order to secure the thickness of a slag film, adjusting the viscosity of a molten slag within a proper range is required.
The viscosity of molten slag for casting at a high casting speed is preferably not greater than 1.5 poise at 1300°C In the case where the viscosity exceeds 1.5 poise, depending on the type of steel, the amount of molten slag flowing into the gap between a mold surface and the solidified shell in a mold may decrease, resulting in longitudinal cracks or difficulty in continuous casting.
Most of the mold powders having chemical compositions defined in the present invention have a solidification temperature of about 1100-1300°C This range of solidification temperature of the mold powder is suitable for casting at a high casting speed. However, in some cases, a mold powder having the chemical composition defined in the present invention has a solidification temperature of 1300°C or more.
In such cases, the Na2 O content is preferably increased so as to lower the solidification temperature of the mold powder. In order to achieve the above-mentioned effects, the Na2 O content is preferably 2% or more. In contrast, if the Na2 O content exceeds 25%, the effect of lowering the solidification temperature does not increase further. Therefore, the Na2 O content is preferably 2-25%. In adjustment of the solidification temperature, if the melting point is decreased, an oxide such as Li2 O is preferably incorporated in addition to Na2 O, and if the solidification temperature is increased, an oxide such as ZrO2 or MgO is preferably incorporated, as appropriate.
Since C, contained in mold powder, burns slowly under continuous casting, C is an effective additive for adjusting the melting rate of mold powder and may be incorporated into mold powder as required. In order to obtain sufficient effect, the C content is preferably 1% or more. However, if the C content exceeds 10%, the melting rate of mold powder is lowered excessively, with the result that continuous casting operation becomes difficult. Consequently, the C content is preferably 1-10%.
As materials used in manufacture of the mold powder of the present invention, those commonly used for mold powder may be used. Examples of CaO sources include burnt lime, limestone, and cement. Examples of SiO2 contain materials include silica sand and diatomaceous earth. Examples of CaF2 contain materials include fluorspar. Examples of Na2 O contain materials include soda ash and sodium carbonate.
The grain size of these materials is preferably 100 μm or less. These materials contain oxides such as Al2 O3, MgO, Fe2 O3, and Fe3 O4. Therefore, the mold powder unavoidably contains these oxides; however, the presence of these impurities does not cause any problems.
By use of the mold powder of the present invention, steel, especially steel containing C in an amount of 0.05-0.20%, can be continuously cast in a stable manner at a high casting speed without longitudinal cracking on the slab surface.
Steel containing C, in an amount of 0.08-0.20%, causes a phase transformation called peritectic reaction. With this phase transformation, a slab surface becomes susceptible to longitudinal cracks. In addition, in casting at a high casting speed, non-uniform cooling influences the solidified shell within a mold, so that a slab surface becomes more susceptible to longitudinal cracks.
Slabs manufactured from a low alloy steel, containing C in an amount of 0.05-0.20%, and an alloy element such as Mn, Cr, Ni, Ti, Mo, Nb, or V, which increases susceptibility to cracking on a slab surface, are susceptible to longitudinal surface cracks, due to the synergistic effect of these alloy elements and C.
Also, slabs manufactured from a low carbon steel, containing C in an amount of about 0.05%, become susceptible to longitudinal surface cracks, when cast at a high casting speed of 5 m/min or higher.
However, by use of the mold powder of the present invention, the above-mentioned steels can be continuously cast at a high casting speed of 5 m/min or higher, without longitudinal cracking on the slab surfaces. Needless to say, the mold powder of the present invention is advantageously used in continuous casting of steels, containing C in an amount of less than 0.05%.
Moreover, in the case where the above-mentioned steels are cast at a low casting speed of about 2.0 m/min by use of the mold powder of the present invention, the thickness of the resultant slag film is sufficiently secured without longitudinal cracks on the surface of a slab.
Slabs each having a thickness of 100 mm and a width of 1000 mm were continuously cast by use of a curved-type continuous casting machine.
Medium carbon steel, low carbon steel, and low-carbon high-Mn steel having the compositions shown in Table 1 were cast at casting speeds of 5 m/min, 6 m/min, and 5 m/min, respectively.
| TABLE 1 |
| ______________________________________ |
| Steel |
| Chemical Composition(*) |
| No. C Si Mn P S sol. A 1 |
| Remark |
| ______________________________________ |
| 1 0.11 0.03 0.49 0.014 |
| 0.004 |
| 0.042 Midium carbon steel |
| 2 0.10 0.02 0.47 0.016 |
| 0.005 |
| 0.039 Midium carbon steel |
| 3 0.05 0.02 0.22 0.014 |
| 0.003 |
| 0.019 Low carbon steel |
| 4 0.05 0.16 1.20 0.023 |
| 0.008 |
| 0.026 Low C-high Mn |
| steel |
| ______________________________________ |
| (*)Unit: % by weight. |
| Balance: Fe and incidental impurities. |
The resultant slabs were tested for longitudinal cracking on their surfaces. The incidence of longitudinal cracking was indicated by Evaluations A to E. The evaluation criteria are as follows:
If the sum of the lengths of longitudinal cracks per mater of a slab is; less than 5 mm: Evaluation A, 5 mm to less than 10 mm: Evaluation B, 10 mm to less than 100 mm: Evaluation C, 100 mm to less than 500 mm: Evaluation D, and 500 mm or more: Evaluation E. Slabs of Evaluations C to E cause problems in product quality when rolled without any processing on the slab surface, whereas slabs of Evaluations A and B cause no problems in practice when rolled without any processing on the slab surface.
In the following Examples, casting tests for slabs using the mold powders of the present invention are considered tests for the continuous casting method of the present invention.
Various medium carbon steels categorized as Steel No. 1 shown in Table 1 were cast, by use of a mold powder of the present invention having a CaO'/SiO2 ratio of 0.9-1.9 and a CaF2 content of 15-60%, or a conventional mold powder having a low basicity for comparison.
| TABLE 2 |
| __________________________________________________________________________ |
| Chemical Evaluation of |
| Composition of Powder (Wt. %) |
| CaO' |
| Solidification |
| Longitudinal |
| Test |
| Steel |
| CaO' CaF2 (F) |
| Na2 O |
| SiO2 |
| Temperature |
| Viscosity |
| Crack on Slab |
| No. |
| No. |
| (*1) |
| SiO2 |
| (*2) (NaF) |
| C (--) |
| (°C) |
| (*3) Surface |
| Remark |
| __________________________________________________________________________ |
| 1 1 22.1 |
| 12.2 |
| 59.7 (29.1) |
| -- -- |
| 1.8 |
| 1195 0.37 A Mold |
| 2 1 22.7 |
| 25.3 |
| 46.0 (22.4) |
| -- -- |
| 0.9 |
| 1135 0.83 B Powder: |
| 3 1 28.2 |
| 18.7 |
| 47.0 (22.9) |
| -- -- |
| 1.5 |
| 1124 0.41 A This |
| 4 1 29.9 |
| 15.7 |
| 48.2 (23.5) |
| -- -- |
| 1.9 |
| 1153 0.27 A Invention |
| 5 1 34.6 |
| 23.2 |
| 36.1 (17.6) |
| -- -- |
| 1.5 |
| 1166 0.34 A |
| 6 1 38.6 |
| 20.4 |
| 35.1 (17.1) |
| (1.6) |
| -- |
| 1.9 |
| 1193 0.38 A |
| 7 1 34.4 |
| 22.5 |
| 33.7 (16.4) |
| 3.8 |
| -- |
| 1.5 |
| 1188 0.41 A |
| 8 1 30.6 |
| 32.2 |
| 21.3 (10.4) |
| 10.2 |
| -- |
| 1.0 |
| 1184 0.33 B |
| 9 1 37.8 |
| 25.5 |
| 20.9 (10.2) |
| 10.1 |
| -- |
| 1.5 |
| 1157 0.32 A |
| 10 1 40.4 |
| 21.7 |
| 22.0 (10.7) |
| 10.3 |
| -- |
| 1.9 |
| 1189 0.25 A |
| 11 1 33.0 |
| 21.6 |
| 18.3 (8.9) |
| 21.5 |
| -- |
| 1.5 |
| 1217 0.19 B |
| 12 1 27.7 |
| 18.3 |
| 47.0 (22.9) |
| -- 1.5 |
| 1.5 |
| 1124 0.41 A |
| 13 1 34.1 |
| 22.9 |
| 36.4 (17.6) |
| -- 1.5 |
| 1.5 |
| 1165 0.34 A |
| 14 1 30.2 |
| 31.8 |
| 21.3 (10.4) |
| 10.2 |
| 1.5 |
| 1.0 |
| 1184 0.33 A |
| 15 1 32.5 |
| 21.2 |
| 18.3 (8.9) |
| 21.5 |
| 1.5 |
| 1.5 |
| 1187 0.41 A |
| 16 1 28.8 |
| 39.4 |
| 17.2 (8.4) |
| 8.1 |
| 1.5 |
| 0.7 |
| 1153 0.71 D Powder: |
| 17 1 25.0 |
| 37.3 |
| 22.3 (10.9) |
| 8.9 |
| 1.5 |
| 0.7 |
| 1194 0.93 D for com- |
| 18 1 19.0 |
| 37.2 |
| 29.1 (14.2) |
| 8.2 |
| 1.5 |
| 0.5 |
| 1053 0.89 E parison |
| __________________________________________________________________________ |
| (*1) Value obtained through Equation (X): CaO' = T. CaO--F × |
| (56/38), wherein T. CaO: the total Ca content in the mold powder as |
| converted to CaO (Wt. %). |
| (*2) Value obtained through Equation (Y): CaF2 = F × (78/38), |
| wherein F: the total F content in the mold powder (Wt. %) |
| (*3) Measurement (poise) at 1300°C |
In Test Nos. 1-15 shown in Table 2, the mold powders of the present invention were used. In Test Nos. 16-18 were used the mold powders for comparison in which the ratio CaO'/SiO2 was below the lower limit defined in the present invention.
Of the mold powders used in Test Nos. 1-15, those used in Test Nos. 1-6 contained CaO, SiO2 and CaF2 as the main components. The mold powder used in Test No. 6 contained a slight amount of NaF as another fluoride in addition to CaF2. The mold powders used in Test Nos. 7-11 contained Na2 O in addition to the aforementioned main components. The mold powders used in Test Nos. 12 and 13 contained C in addition to the aforementioned main components. The mold powders used in Test Nos. 14 and 15 contained Na2 O and C in addition to the aforementioned main components. The mold powders used in Test Nos. 1-15 have a viscosity of 0.19-0.83 poise at 1300°C and a solidification temperature of 1124-1217°C
Slabs which had undergone casting by use of these mold powders were evaluated for longitudinal cracks on their surfaces, resulting in Evaluation A, which represents "excellent," in all cases except those in Test Nos. 2, 8, and 11.
The mold powders used in Test Nos. 2 and 8 had relatively small CaO'/SiO2 ratios, 0.9 and 1.0 respectively, so that their crystallization amounts were small and mild cooling effects to slabs surface were somewhat small. Consequently, longitudinal cracks on slabs using these mold powders were all evaluated as Evaluation B.
The mold powder used in Test No. 11 had a slightly low viscosity of 0.19 at 1300°C, and longitudinal cracks of slabs cast by use of the mold powder were evaluated as Evaluation B. The mold powder used in Test No. 14 had a low CaO'/SiO2 ratio of 1∅ No longitudinal cracks were caused in the slab, since C had been incorporated into the mold powder so as to adjust the melting rate of the mold powder.
The mold powders used for comparison in Test Nos. 16-18 contained CaO, SiO2, and CaF2, which are the main components of the mold powders of the present invention, and additionally contained Na2 O and C. However, these powders had a CaO'/SiO2 ratio of 0.5-0.7, which is below the lower limit defined in the present invention.
The slabs which had undergone casting by use of these mold powders for comparison having a low basicity suffered conspicuous longitudinal cracks which were evaluated as Evaluation D or E. Consequently, it was confirmed that use of a mold powder having a CaO'/SiO2 ratio below the lower limit 0.9, which is defined in the present invention, is disadvantageous in casting of medium carbon steel at a high casting speed of 5 m/min, since this leads to lowered slab surface quality.
Various medium carbon steels which are categorized as Steel No. 2 shown in Table 1 were cast, by use of a mold powder of the present invention having a CaO'/SiO2 ratio of greater than 1.9 and not greater than 2.8 and a CaF2 content of 5-60%, or a conventional mold powder having a low basicity for comparison.
| TABLE 3 |
| __________________________________________________________________________ |
| Chemical Evaluation of |
| Composition of Powder (Wt. %) |
| CaO' |
| Solidification |
| Longitudinal |
| Test |
| Steel |
| CaO' CaF2 (F) |
| Na2 O |
| SiO2 |
| Temperature |
| Viscosity |
| Crack on Slab |
| No. |
| No. |
| (*1) |
| SiO2 |
| (*2) (NaF) |
| C (--) |
| (°C) |
| (*3) Surface |
| Remark |
| __________________________________________________________________________ |
| 19 2 36.2 |
| 15.4 |
| 47.6 (23.2) |
| -- 1.5 |
| 2.4 |
| 1219 0.38 A Mold |
| 20 2 45.3 |
| 19.3 |
| 34.8 (17.0) |
| (1.4) |
| 1.5 |
| 2.3 |
| 1224 0.41 A Powder: |
| 21 2 44.4 |
| 19.0 |
| 30.5 (15.0) |
| 3.0 |
| 1.5 |
| 2.3 |
| 1114 0.37 A This |
| 22 2 44.8 |
| 18.8 |
| 21.7 (10.6) |
| 8.1 |
| 1.5 |
| 2.4 |
| 1163 0.31 A Invention |
| 23 2 49.5 |
| 19.2 |
| 12.3 (6.0) |
| 12.1 |
| 1.5 |
| 2.6 |
| 1187 0.34 B |
| 24 2 49.4 |
| 20.8 |
| 10.1 (5.0) |
| 15.3 |
| 1.5 |
| 2.4 |
| 1189 0.37 B |
| 25 2 52.1 |
| 19.4 |
| 7.1 (3.6) |
| 18.4 |
| 1.5 |
| 2.7 |
| 1195 0.36 A |
| 26 2 44.4 |
| 19.0 |
| 30.5 (15.0) |
| 3.0 |
| 0.5 |
| 2.3 |
| 1194 0.37 B |
| 27 2 32.7 |
| 40.1 |
| 16.2 (8.0) |
| 8.9 |
| 1.5 |
| 0.8 |
| 1192 0.78 E Powder: |
| 28 2 52.9 |
| 20.8 |
| 2.3 (1.2) |
| 22.6 |
| 1.5 |
| 2.5 |
| 1450 -- -- for com- |
| parison |
| __________________________________________________________________________ |
| (*1) Value obtained through Equation (X): CaO' = T. CaO--F × |
| (56/38),wherein T. CaO: the total Ca content in the mold powder as |
| converted to CaO (Wt. %). |
| (*2) Value obtained through Equation (Y): CaF2 = F × (78/38), |
| wherein F: the total F content in the mold powder (Wt. %) |
| (*3) Measurement (poise) at 1300°C |
In Test Nos. 19-26 shown in Table 3, the mold powders of the present invention were used. In Test Nos. 27 and 28 were used the mold powders for comparison in which the ratio CaO'/SiO2 or the CaF2 content was below the lower limit defined in the present invention.
Of the mold powders used in Test Nos. 19-26, those used in Test Nos. 19 and 20 contained C in addition to the main components, i.e. CaO, SiO2, and CaF2. The mold powders used in Test Nos. 21-26 contained Na2 O and C in addition to the main components. The mold powder used in Test No. 20 contained a slight amount of NaF as another fluoride in addition to CaF2. These mold powders used in Test Nos. 19-26 had a viscosity of 0.31-0.41 poise at 1300°C and a solidification temperature of 1163-1224°C
Slabs which had undergone casting by use of these mold powders were evaluated for longitudinal cracks on their surfaces, resulting in Evaluation A, which represents "excellent," in all cases except those in Test Nos. 23, 24, and 26. The mold powders used in Test Nos. 23 and 24 had a CaO'/SiO2 ratio of 2.4-2.6; however, they had a low CaF2 content of 10-12%, so that the flow amounts of their molten slag into the gap between a mold surface and a solidified shell were somewhat small. Consequently, longitudinal cracks on slabs cast by use of these mold powders were evaluated as Evaluation B.
The mold powder used in Test No. 25 also had a low CaF2 content of 7%; however, it had a high CaO'/SiO2 ratio of 2.7, so that its crystallization amount was large. Consequently, longitudinal cracks of slabs cast by use of the mold powder were evaluated as Evaluation A (excellent).
The mold powder used in Test No. 26 had a low C content of 0.5%, so that the thickness of its molten slag became excessively large and the flow amount of the molten slag became non-uniform. Consequently, longitudinal cracks of slabs cast by use of the mold powder were evaluated as Evaluation B.
The mold powder used for comparison in Test No. 27 contained CaO, SiO2, and CaF2, which are the main components of the mold powders of the present invention, and additionally contained Na2 O and C. However, this powder had a CaO'/SiO2 ratio of 0.8, which is below the lower limit defined in the present invention.
The slab for comparison which had undergone casting by use of this mold powder suffered conspicuous longitudinal cracks which were evaluated as Evaluation E. Consequently, it was confirmed that using a mold powder having a CaO'/SiO2 ratio below the lower limit 0.9 defined in the present invention is disadvantageous in casting of medium carbon steel at a high casting speed of 5 m/min, since this leads to lowered slab surface quality.
The mold powder used for comparison in Test No. 28 had a CaO'/SiO2 ratio of 2.5; however, it had a CaF2 content of 2.3%, which is below the lower limit defined in the present invention.
For this reason, the solidification temperature of this mold powder had a high solidification temperature of 1450°C, which made casting difficult. As a result, this mold powder was not used in casing tests for medium carbon steel.
Various low carbon steels which are categorized as Steel No. 3 shown in Table 1 were cast, by use of a mold powder of the present invention having a CaO'/SiO2 ratio of 0.9-1.9 and a CaF2 content of 15-60%, or a conventional mold powder having a low basicity for comparison.
| TABLE 4 |
| __________________________________________________________________________ |
| Chemical Evaluation of |
| Composition of Powder (Wt. %) |
| CaO' |
| Solidification |
| Longitudinal |
| Test |
| Steel |
| CaO' CaF2 (F) |
| Na2 O |
| SiO2 |
| Temperature |
| Viscosity |
| Crack on Slab |
| No. |
| No. |
| (*1) |
| SiO2 |
| (*2) (NaF) |
| C (--) |
| (°C) |
| (*3) Surface |
| Remark |
| __________________________________________________________________________ |
| 29 3 29.8 |
| 21.3 |
| 45.8 (22.3) |
| -- 1.5 |
| 1.4 |
| 1196 0.42 A Powder of |
| 30 3 30.1 |
| 20.2 |
| 49.9 (24.3) |
| 0.8 |
| 2.0 |
| 1.5 |
| 1219 0.40 A Invention |
| 31 3 25.1 |
| 31.4 |
| 18.9 (9.2) |
| 9.6 |
| 2.0 |
| 0.8 |
| 1134 0.79 B Another |
| 32 3 26.3 |
| 32.8 |
| 19.3 (9.4) |
| 9.0 |
| 2.0 |
| 0.8 |
| 1145 0.88 B Powder |
| __________________________________________________________________________ |
| (*1) Value obtained through Equation (X): CaO' = T. CaO--F × |
| (56/38), wherein T. CaO: the total Ca content in the mold powder as |
| converted to CaO (Wt. %). |
| (*2) Value obtained through Equation (Y): CaF2 = F × (78/38), |
| wherein F: the total F content in the mold powder (Wt. %) |
| (*3) Measurement (poise) at 1300°C |
| TABLE 5 |
| __________________________________________________________________________ |
| Chemical Evaluation of |
| Composition of Powder (Wt. %) |
| CaO' |
| Solidification |
| Longitudinal |
| Test |
| Steel |
| CaO' CaF2 (F) |
| Na2 O |
| SiO2 |
| Temperature |
| Viscosity |
| Crack on Slab |
| No. |
| No. |
| (*1) |
| SiO2 |
| (*2) (NaF) |
| C (--) |
| (°C) |
| (*3) Surface |
| Remark |
| __________________________________________________________________________ |
| 33 4 29.2 |
| 20.3 |
| 54.0 (26.3) |
| -- 1.5 |
| 1.4 |
| 1168 0.38 A Powder of |
| 34 4 30.4 |
| 22.2 |
| 48.4 (23.6) |
| 0.8 |
| 2.0 |
| 1.4 |
| 1209 0.41 A Invention |
| 35 4 22.8 |
| 32.4 |
| 20.7 (10.1) |
| 9.0 |
| 2.0 |
| 0.7 |
| 1165 0.81 C Another |
| 36 4 22.2 |
| 31.5 |
| 18.5 (9.0) |
| 9.0 |
| 2.0 |
| 0.7 |
| 1187 0.69 B Powder |
| __________________________________________________________________________ |
| (*1) Value obtained through Equation (X): CaO' = T. CaO--F × |
| (56/38), wherein T. CaO: the total Ca content in the mold powder as |
| converted to CaO (Wt. %). |
| (*2) Value obtained through Equation (Y): CaF2 = F × (78/38), |
| wherein F: the total F content in the mold powder (Wt. %) |
| (*3) Measurenent (poise) at 1300°C |
In Test Nos. 29 and 30 shown in Table 4, the mold powders of the present invention were used. In Test Nos. 31 and 32 were used the mold powders for comparison in which the ratio CaO'/SiO2 was below the lower limit defined in the present invention.
The mold powder used in Test Nos. 29 and 30 contained CaO, SiO2 and CaF2, which are the main components of the mold powders of the present invention, and additionally contained C exclusively or Na2 O and C. These mold powders had a CaO'/SiO2 ratio of 1.4-1.5, a CaF2 content of 45-50%, a viscosity of 0.40-0.42 poise at 1300°C, and a solidification temperature of 1196-1219°C
Slabs which had undergone casting by use of these mold powders were evaluated for longitudinal cracks on their surfaces, resulting in Evaluation A, which represents "excellent."
The mold powders used for comparison in Test No. 31 and 32 contained CaO, SiO2 and CaF2 which are the main components of the mold powders of the present invention, and additionally contained Na2 O and C. However, this powder had a CaO'/SiO2 ratio of 0.8, which is below the lower limit defined in the present invention.
Slabs cast by use of these low-basicity mold powders for comparison were evaluated for longitudinal cracks, resulting in Evaluation B. The reason why these slabs suffered only a few longitudinal cracks is that they were manufactured from low carbon steel, which generally results in a few longitudinal cracking on its slab surface. However, Evaluation B for the longitudinal cracks on the surfaces of slabs cast by use of these mold powders for comparison was lower than Evaluation A for the longitudinal cracks on the surfaces of slabs cast by use of the mold powder of the present invention. Therefore, it was confirmed that the mold powder of the present invention having a high basicity is advantageously used in casting of low carbon steel at a high casting speed of 6 m/min.
Various low-carbon high-Mn steels which are categorized as Steel No. 4 shown in Table 1 were cast, by use of a mold powder of the present invention having a CaO'/SiO2 ratio of 0.9-1.9 and a CaF2 content of 15-60%, or a conventional mold powder having a low basicity for comparison.
In Test Nos. 33 and 34 shown in Table 5, the mold powders of the present invention were used. In Test Nos. 35 and 36 were used the mold powders for comparison in which the ratio CaO'/SiO2 was below the lower limit defined in the present invention.
The mold powder used in Test Nos. 33 and 34 contained CaO, SiO2 and CaF2, which are the main components of the mold powders of the present invention, and additionally contained C exclusively or Na2 O and C. These mold powders had a CaO'/SiO2 ratio of 1.4, a CaF2 content of 48-54%, a viscosity of 0.38-0.41 poise at 1300°C, and a solidification temperature of 1168-1209°C
Slabs which had undergone casting by use of these mold powders were evaluated for longitudinal cracks on their surfaces, resulting in Evaluation A, which represents "excellent."
The mold powders used for comparison in Test No. 35 and 36 contained CaO, SiO2 and CaF2 which are the main components of the mold powders of the present invention, and additionally contained Na2 O and C. However, these powders had a CaO'/SiO2 ratio of 0.7, which is below the lower limit defined in the present invention.
Slabs cast by use of these mold powders for comparison were evaluated for longitudinal cracks, resulting in Evaluation B or C. Consequently, it was confirmed that use of a mold powder having a CaO'/SiO2 below the lower limit 0.9 defined in the present invention is disadvantageous in casting of low-carbon high-Mn steel at a high casting speed of 5 m/min, since this leads to lowered slab surface quality.
Kumakura, Seiji, Kawamoto, Masayuki, Hanao, Masahito, Tanizawa, Yoshinori
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